CONSTELLATION DRIVING LIGHT BAR 5001 - Cycle Gear

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INSTALLATIONCONSTELLATION DRIVING LIGHT BAR5001877.370.3604 (toll free)PARTS INCLUDED1111111CUSTOMER SERVICEConstellation Driving Light Bar AConstellation Driving Light Bar BAdjustable Driving Light MaskDriving Light with Turn Signal RightDriving Light with Turn Signal LeftHardware Kit Containing:21/4”-20 x1” Button Socket Cap Screws8Insulated Male Spades8Female T-Tap Connectors84” Cable Ties15/32” Short Hex Wrench2Dielectric Grease Packs21/4-20 x 1/2” Button Socket Cap Screws21/4” Flat Washers2#10-24 x 5/16” Button Socket Cap ScrewsInstallation InstructionsPlease read and understand entire instructions before starting installation.THANK YOU FOR CHOOSING KϋRYAKYN!IN ORDER TO PROTECT YOU AND OTHERS FROM POSSIBLE INJURY AND/ORPROPERTY DAMAGE OR LOSS, PLEASE PAY CLOSE ATTENTION TO ALLINSTRUCTIONS, WARNINGS, CAUTIONS AND NOTICES REGARDING THE USEAND CARE OF THIS PRODUCT.THIS INDICATION ALERTS YOU TO THE FACT THATIGNORING THE CONTENTS DESCRIBED HEREIN CANRESULT IN POTENTIAL DEATH OR SERIOUS INJURY.This indication alerts you to the fact that ignoring thecontents described herein may negatively affect productperformance and functionality.This indication alerts you to the fact that ignoringthe contents described herein can result in potentialinjury.IF INSTALLING THIS PRODUCT FOR ANOTHER PARTY,PLEASE MAKE SURE THEY RECEIVE THIS COPY OF THEINSTALLATION INSTRUCTIONS SO THEY ARE AWARE OFTHE IMPORTANT INFORMATION CONTAINED IN THEM.TOOLS SUGGESTEDSet of Hex Wrenches, Drill and 1/8" Drill Bit, Wire Strippers/Crimpers, Test Light, and a Marker.STRICTLY OBSERVE THE FOLLOWING GUIDELINES IN ORDER TO USE THEPRODUCT PROPERLY AND AVOID POTENTIALLY DANGEROUS ACCIDENTS.STEP 1Read and understand all steps in the instructions before starting theinstallation. Park the motorcycle on a hard, level surface and turn off theignition.5001-22MC-0513-cont.-INSTALLATION QUESTIONStechsupport@kuryakyn.comor call 715.247.2983LIMITED WARRANTYKüryakyn warrants that any Küryakyn productssold hereunder, shall be free of defects inmaterials and workmanship for a period of one(1) year from the date of purchase by theconsumer excepting the following provisions: Küryakyn shall have no obligation in the eventthe customer is unable to provide a receiptshowing the date the customer purchased theproduct(s). The product must be properly installed,maintained and operated undernormal conditions. Küryakyn makes no warranty, expressed orimplied, with respect to any gold platedproducts. Küryakyn shall not be liable for anyconsequential and incidental damages, includinglabor and paint, resulting from failure of aKüryakyn product, failure to deliver, delay indelivery, delivery in nonconforming condition, orfor any breech of contract or duty betweenKüryakyn and a customer. Küryakyn products are often intended for use inspecific applications. Küryakyn makes nowarranty if a Küryakyn product is used inapplications other than intended. Küryakyn electrical products are warranted forone (1) year from the date of purchase by theconsumer. L.E.D.’S contained in components ofKüryakyn products will be warranted for defectsin materials and workmanship for 3 years fromthe date of purchase where as all othercomponents shall be warranted for one(1) year.This includes, but is not limited to; controlmodules, wiring, chrome & other components. Küryakyn makes no warranty of any kind inregard to other manufacturer¹s productsdistributed by Küryakyn. Küryakyn will pass onall warranties made by the manufacturer andwhere possible, will expedite the claim on behalfof the customer, but ultimately, responsibility fordisposition of the warranty claim lieswith the manufacturer.ABOUT OUR CATALOGFor purchasing Küryakyn products, youcan receive a complete catalog free of charge.Send the Proof-of-Purchase below withyour address to: Küryakyn, P.O. Box 339,Somerset, WI 54025.Please indicate either Accessories Catalog forHarley-Davidson or GL & Metric Cruisers.Be sure to ask your local dealer about otherKüryakyn products, the motorcycle parts andaccessories designed for riders by riders. 2005 Küryakyn USA All Rights reserved.

NOTE:For installation with model specific Küryakyn mounting bracket (purchased separately).NOTE: Küryakyn recommends using one of our Driving Light andPIC 1CENTER LINECENTER LINESwitch/Relay Harnesses, P/N 2202 or P/N 2328 (following theirincluded instructions) to power the lights to prevent overloadinga circuit on the bike. You may install the black power wires fromthe driving lights using the female t-tap connectors and connectthem to a “keyed” power source. The lights draw approximately 6amps. Before connecting the power wires to a circuit check tomake sure that the circuit can handle the additional load.IT IS THE INSTALLERS RESPONSIBILITY TO ENSURETHAT THE INSTALLATION OF THIS ACCESSORY DOESNOT EXCEED THE MAXIMUM AMPERAGE OF THEFORWARDCHOSEN CIRCUIT. EXCEEDING THE MAXIMUMALLOWABLE AMPERAGE MAY LEAD TO CIRCUIT FAILUREWHICH COULD RESULT IN SERIOUS INJURY OR DEATH.A FACTORY SERVICE MANUAL WILL BE HELPFUL INPERFORMING THIS INSTALLATION. DO NOT ATTEMPT TOPERFORM THIS INSTALLATION IF YOU ARE NOT CONFIDENTIN YOUR ABILITY TO COMPLETE ALL OF THE STEPS IN THEPROCEDURE; CONSULT A TRAINED TECHNICIAN. IMPROPERINSTALLATION COULD RESULT IN SERIOUS INJURY ORDEATH.REARWARDPIC 2ROUTE WIRESTHROUGH BARMOUNTING HOLESPIC 3STEP 2Determine which position the lights will be mounted in; either the forward or rearposition as shown in PIC. 1 (switch the light bar to the other set of lights toachieve this, as each bar is directional).STEP 3Once the positioning has been determined, carefully route the wires from thelights through the bar as shown in PIC. 2 and secure the bar to the lights using anincluded 1/4”-20 x1” button socket cap screw as shown in PIC. 3.STEP 4Repeat STEP 3 for the other side.STEP 5Place the light bar on the adapter bracket and secure with an included1/4”-20 x 1/2” button socket cap screw and 1/4” flat washer.SECURE THE LIGHT TO THEBAR WITH THE 1/4”-20 X 1”BUTTON SOCKET CAP SCREWPIC 4SECURE THE MASK TO THE BARWITH THE #10-24 X 5/16”BUTTON SOCKET CAP SCREWSNOTE: There are three different mounting holes in the bottom of the light bar(PIC. 2) to adjust the overall width of the lights when they are installed.STEP 6Repeat STEP 5 for the other lights and mounting bar.STEP 7Route the wires down through the holes in the adapter bracket.STEP 8Place the adjustable driving light mask over the light bars so that the holes are inthe back and secure the mask to the bars with the included #10-24 x 5/16” button socket capscrews.STEP 9On Metric Models: Remove the headlight and route the wires into the headlight housing throughthe hole at the back of the housing.On FLSTF Models: Route the wires under the bottom triple tree and into the rear of the forkshrouds.STEP 10Turn the handlebars lock to lock to make sure there is clearance between the lights and anycomponent on the motorcycle.PAGE2-cont.-CONSTELLATION DRIVING LIGHTSINSTALLATION

TURN THE FORK LOCK TO LOCK TO CHECK FOR CLEARANCE BETWEENTHE LIGHTS AND ANY OTHER COMPONENT ON THEMOTORCYCLE. INSUFFICIENT CLEARANCE MAY CAUSE LOSS PIC 5OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.Secure all wiring from the newly installed and/or from existing parts,away from any moving parts, pinch points or extreme heat. KüryakynWILL NOT issue a warranty on any electrical component that failsdue to pinched, crimped, broken, abraded, melted or frayed wires.It is the installer’s responsibility to ensure that all of the fasteners(including pre-assembled) are tightened before operation of themotorcycle. Küryakyn will not provide warranty coverage on productsor components lost due to improper installation or lack ofPIC 6maintenance. Periodic inspection and maintenance are required onall fasteners.WIRING PROCEDUREWiring Color Codes for Driving Lights and Turn SignalsColorFunctionBlackGroundViolet“High” Turn SignalBlue“Low” running lightWhiteDriving Lights Power WireSTEP 11Identify the stock turn signal wiring harness; refer to your factory service manualto locate the harness.STEP 12Turn the key “ON” and using a test light or the wiring diagram for your bike,determine the left and right turn signal power, running light power and a groundwire. Label each of these wires for their function or write the color and functiondown. Turn the key “OFF” and disconnect the battery.PIC 7NOTE: On some motorcycles (i.e. ’05-up Honda VTX 1800 models) there will onlybe one wire for the running lights and turn signals; in this situation, boththe turn signal wire and running light wire will need to be connected to this wire.STEP 13Place one of the included female T-Tap connectors over each wire and close them,ensuring that the tabs are engaged as shown in PIC 5Avoid potential electrical shock! Disconnect the battery before startingthis procedure.STEP 14Using wire strippers remove a small amount of insulation from the ends of the wires from the newturn signals.STEP 15Insert each individual exposed end of the violet, blue and black wires into their own male spadeand crimp the end making sure that the wire is secure. PIC 6 If you are going to use a chassisground for the lights, do not install a male spade to the black wires.Küryakyn recommends the use of dielectric grease on electrical connections.STEP 16Place a small amount of dielectric grease on the female T-Tap connectors and insert the malespade connectors from the left side turn signal’s violet wire into the female T-Tap installed on theleft signal wire. Insert the male spade connectors from the right side turn signal’s violet wire intothe female T-Tap installed on the right signal wire. Insert the male spade connectors from bothblue wires into the female T-Tap connectors installed on the running light wire(s). PIC 7PAGE3-cont.-CONSTELLATION DRIVING LIGHTSINSTALLATION

STEP 17Connect the black wires from the signals to a chassis ground, or a known wiring harness ground.STEP 18Küryakyn recommends using one of our Driving Light Switch/Relay Harnesses, P/N 2202 orP/N 2328 (following their included instructions) to power the Driving Lights to prevent overloadinga circuit on the bike. Proceed to Step 21, if using the Driving light Switch/Relay Harness.STEP 19If you decide to install the lights to the existing wiring on the bike, proceed as follows: Reconnectthe battery. Using a test light or wiring schematic, with the key in the “ON” position, locate a“keyed” 12-volt power wire (a wire that has power with the key “ON” and loses power with thekey “OFF”)to power the driving lights. Once you have located a keyed 12-volt power source, turnthe key to the “OFF” position and disconnect the battery.STEP 20Take two of the included female T-Tap connectors and place them on the desired power wire.Take the white power wires from each light and connect them to the female T-Taps on this wire.Secure all excess wiring out of harms way with the included cable ties.Secure all wiring from the newly installed and/or from existing parts, away fromany moving parts, pinch points or extreme heat. Küryakyn WILL NOT issue awarranty on any electrical component that fails due to pinched, crimped, broken,abraded, melted or frayed wires.STEP 21Once all connections are connected, reconnect the battery. Reinstall the seat. Turn the key to the“ON” position and check to ensure all lights work properly.ENSURE PROPER LIGHT OPERATION BEFORE RIDING THE MOTORCYCLE.VISIBILITY IS A MAJOR CONCERN FOR MOTORCYCLISTS. A LIGHTINGMALFUNCTION COULD RESULT IN DEATH OR SERIOUS INJURY.AFTER INSTALLING THE SEAT, PULL UP ON IT TO ENSURE IT IS LOCKEDINTO PLACE. A LOOSE SEAT CAN SHIFT AND CAUSE LOSS OF CONTROLRESULTING IN SERIOUS INJURY OR DEATH.STEP 22If lights do not work, go over the wire connections and check all plugs to see if they areplugged-in correctly. You may also have to use a test light again check and see if the spade/T-Tapconnectors are in the proper locations.STEP 23Secure all fasteners.It is the installer’s responsibility to ensure that all of the fasteners (includingpre-assembled) are tightened before operation of the motorcycle. Küryakyn willnot provide warranty coverage on products or components lost due to improperinstallation or lack of maintenance. Periodic inspection and maintenance arerequired on all fasteners.ADJUSTING THE DRIVING LIGHTSIT IS THE INSTALLERS RESPONSIBILITY TO ADJUST THE NEW DRIVINGLIGHTS TO THE PATTERN RECOMMENDED IN THE SERVICE MANUAL FORTHE HEADLIGHT LOW BEAM. FAILURE TO PROPERLY ADJUST THE LIGHTPATTERN MAY DISTRACT ONCOMING DRIVERS RESULTING IN SERIOUSINJURY OR DEATH.STEP 1For up and down adjustment, loosen the fastener that secures the light assembly to the barand tilt the assembly in the desired direction. When the light is in the desired position, tighten thefastener securely.PAGE4-cont.-CONSTELLATION DRIVING LIGHTSINSTALLATION

STEP 2For side to side adjustment, remove the glass light housing as outlined below,loosen the fastener inside the light housing. Rotate the housing to the desiredposition and retighten the fastener. Reinstall the lightPIC 8It is the installer’s responsibility to ensure that all of the fasteners(including pre-assembled) are tightened before operation of themotorcycle. Küryakyn will not provide warranty coverage onproducts or components lost due to improper installation or lack ofmaintenance. Periodic inspection and maintenance are required onall fasteners.REMOVE THIS SCREWREPLACING THE LIGHT BULBSTEP 1ROTATE THIS DIRECTION TO REMOVEAs shown in PIC 8, remove the Button Head Cap Screw located at the bottom ofthe light housing.STEP 2Remove the light bezel by twisting the bezel counter clockwise and pulling thebezel outward.STEP 3Remove the rubber inner seal from the chrome light housing. The glass lighthousing should now be free.PIC 9THESE UNPLUGNOTE: Please note the orientation of the locating ring. This will greatly helpwhen reassembling the lights. PIC 10.STEP 4Pull the glass housing out away from the chrome housing and disconnect thewires. PIC 9.STEP 5As shown in PIC 10, remove the 4 screws to gain access to the light bulb. Pull thelight bulb from the mount with the white wire attached.STEP 6Take the new light and insert the white wire through the mount from the frontside. (The wire should fit through the rubber boot on the backside of the mount).Do not handle the glass portion of the new bulb with your bare hands. Oilfrom your fingers will stay on the bulb and create a hot spot, shorteningthe life of the bulb. If you do touch the bulb, clean it with an ammoniabased cleaner, such as window cleaner or with alcohol before installation.STEP 7PIC 10LOCATING RINGREMOVE THESE SCREWSReassemble the glass housing and the chrome housing in the reverse order they weredisassembled.It is the installer’s responsibility to ensure that all of the fasteners (includingpre-assembled) are tightened before operation of the motorcycle. Küryakyn willnot provide warranty coverage on products or components lost due to improperinstallation or lack of maintenance. Periodic inspection and maintenance arerequired on all fasteners.PAGE4Ride On!CONSTELLATION DRIVING LIGHTSINSTALLATION

NOTE: On some motorcycles (i.e. ’05-up Honda VTX 1800 models) there will only be one wire for the running lights and turn signals; in this situation, both the turn signal wire and running light wire will need to be connected to this wire. STEP 13 Place one of the included female T-Tap connectors over each wire and close them,

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